Disposable garment

ABSTRACT

This invention pertains to a three dimensional disposable garment, subassemblies of the garment, and apparatus and methods for making the garment and subassemblies. The garment is designed to hold a primary absorbent sanitary pad. The garment may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. The garment provides backup protection to control egress of fluids that leak or seep around or through the primary sanitary pad. The garment includes a secondary absorbent positioned in the crotch area and extending into the body of the disposable garment, front and back, and preferably over the leg elastics to trap, inside the garment, leakage from the primary absorbent, and to prevent strike through onto e.g. outer clothing and bed linen. The apparatus and methods facilitate assembling leg elastics and crotch elastics into the garment subassemblies while assembling a series of garment subassemblies in a continuous web structure at a constant, or relatively constant, continuous and efficient speed.

This application is a Divisional of prior application Ser. No.08/382,108, filed on Jan. 31, 1995, now U.S. Pat. No. 5,745,922.

FIELD OF THE INVENTION

This invention relates to undergarments in general, and morespecifically to women's disposable undergarments having an absorbentlayer or fluid repellent region or both to be used with a woman's normalfeminine care protection during her menstrual period.

BACKGROUND OF THE INVENTION

Regular undergarments in current use are made of cotton and/or syntheticmaterials. The cotton and synthetic panties typically do not offerbarrier protection. Often the synthetic panties have a cotton linedcrotch to absorb vaginal discharges or perspiration. Theabsorbent/barrier properties of regular undergarments are minimal suchthat any vaginal discharge and/or heavy perspiration may strike throughonto outer clothing (i.e. liquid penetrates from the interior to theexterior of the undergarment.)

Panty liners and feminine care sanitary napkins or pads used withregular undergarments have polyethylene backings that provide somebarrier properties inhibiting liquid strike through. However, if thevaginal discharge extends to the sides or the ends of the pads it canleak or seep around an edge of the pad and onto the undergarment. Suchleakage can stain the undergarment. Depending upon the amount ofleakage, liquid may strike through or go around the undergarment andstain outer clothing and/or bedding. Women with heavy liquid flows mayuse one or more maxi pads, double pads and/or tampons alone, or incombination, and change these pads and tampons frequently to preventembarrassing, messy leakage around the edges of the pads and/or stainingof outer clothing. In some cases, during their heaviest flow days, somewomen will restrict their activities and stay home.

Many women experience some leakage of menses from their pads to theirundergarments. This varies from being limited to a small number of padsleaking onto only the undergarment during light flow to more prevalentleakage onto the wearer's outer clothing on pads worn during heavy flow.Normally this leakage occurs at the side of the pad, although endleakage is also a problem. Placement of maxi pads and overnight pads inthe crotch of regular undergarments shows that, at best, the pads lay onthe leg elastic and, at worst, overhang the leg elastics. This causesside leakage onto the undergarment and possibly onto outer clothing.Typical leakage from the pad is caused by poor fit of the pad to thebody, improper positioning of the pad by the user and lack ofabsorbency. Leakage from the undergarment onto the outer clothing istypically due to incompatibility between the pad width and theundergarment crotch width and/or lack of barrier properties in theundergarment material around the edge portion of the pad.

SUMMARY OF THE INVENTION

This invention describes a three dimensional, disposable, discretegarment, subassemblies of the garment, and apparatus and methods formaking the garment.

First the invention describes a garment blank subassembly which is atype of precursor of the garment. The subassembly has a front bodyportion, a back body portion, and an intermediate crotch extending fromthe front body portion to the back body portion and between a pair ofleg cutouts for defining leg openings in the garment to be assembledfrom the garment blank subassembly. The front body portion has first andsecond front leg edge portions along the leg cutouts. The back bodyportion has third and fourth back leg edge portions along the legcutouts. Fifth and sixth crotch edge portions are disposed on opposingsides of the crotch along the leg cutouts. The front body portion has afront waist portion at a first edge of the garment blank subassembly.The back body portion has a back waist portion at a second edge of thegarment blank subassembly opposite the first edge, the front and backbody portions, in combination, defining opposing third and fourth sideedges of the garment blank subassembly. The garment blank subassemblyhas a length extending between the first and second edges, and a widthextending between the third and fourth edges. Each of the third andfourth back leg edge portions has a first angular portion extendinggenerally along a line forming an acute angle with an imaginarycenterline extending between the first and second edges, and a secondarcuate portion having a third end at the respective first angularportion and a fourth end connecting the respective back leg edge portionto the respective one of the fifth and sixth crotch edge portions. Thegarment blank subassembly, when laid out flat, comprises a firstoperative layer, generally extending functionally from the first edgethrough the crotch to the second edge; a second layer secured to thefirst layer; and one or more threads of elastic between and secured tothe first and second layers, and extending continuously from a firstlocus adjacent the third side edge, as a first section, along the widthof the garment blank subassembly, toward the first edge at an acuteangle with the centerline and generally following the third back legedge portion toward the crotch, as a second section across the crotch,and as a third section along the width of the garment blank subassemblyand away from the first edge at an acute angle with the centerline andgenerally following the fourth back leg edge portion, to a second locusadjacent the fourth side edge.

Preferably, the first and third sections of elastic are stretched whenthe garment blank subassembly is laid out flat, and the second sectionof elastic is substantially relaxed.

In preferred embodiments, the elastic extends across the crotch betweenthe two fourth ends of the second arcuate portions and parallel to thesecond edge of the garment blank subassembly.

In some embodiments, it is preferred that the second section of elasticbe disposed and secured between the first and second layers.

Typically, the second layer comprises a body side liner having a frontlayer element secured to the front portion of the first layer, and aback layer element secured to the back portion of the first layer, withan unsecured space disposed between the front layer element and the backlayer element, the unsecured space generally corresponding with thecrotch portion of the garment blank subassembly, the second section ofelastic preferably being disposed in the unsecured space, between thefront and back layer elements of the first layer.

The term "unsecured space" may include an area where the front layerelement and the back layer element of the second layer may or may not becontiguous and which at least a portion of the front and/or back layerelements remain unsecured to the first layer or an area on the firstlayer between the front layer element and the back layer element whichlacks a second layer. The unsecured areas do not include those zonestypically formed between swirls or lines of adhesive but rather blockzones lacking adhesive or other bonding applications.

Further to preferred embodiments, each of the first and second front legedge portions has a first longitudinal portion extending generally alongthe width of the garment blank subassembly and a second arcuate portionhaving a first end at the,respective first longitudinal portion and asecond end connecting the respective front leg edge portion to therespective one of the fifth and sixth crotch edge portions, the garmentblank subassembly including a separate thread of elastic between andsecured to the first and second layers and extending from a third locusadjacent the third side edge, as a fourth section of elastic, along thewidth of the garment blank subassembly, generally following the firstfront leg edge portion along the first longitudinal portion and along atleast part of the respective first arcuate portion, away from the firstedge, to the crotch, as a fifth section across the crotch, and as asixth section along at least part of the respective second arcuateportion of the respective front leg edge portion, toward the first edgeand generally following the second front leg edge portion along thesecond longitudinal portion to a fourth locus adjacent the fourth sideedge.

Preferably, a second and optionally additional threads of elastic followa path generally parallel to the path followed by the first thread ofelastic. Additional threads of elastic may be disposed along the fifthand sixth crotch edge portions.

Second, the invention comprehends a garment blank subassembly whereineach of the first and second front leg edge portions has a longitudinalportion extending generally along the width of the garment blanksubassembly and a first arcuate portion having a first end at therespective first longitudinal portion and a second end connecting therespective front leg edge portion to the respective one of the fifth andsixth crotch edge portions, and wherein one or more threads of elasticare disposed between and secured to the first and second layers, andextend continuously from a first locus adjacent the third side edge, asa first section, along the width of the garment blank subassembly,generally following the first front leg edge portion along its firstlongitudinal portion and along at least part of the respective firstarcuate portion, away from the first edge, toward the crotch, as asecond section across the crotch, and as a third section along at leastpart of the respective first arcuate portion, toward the first edge andgenerally following the second front leg edge portion along the secondlongitudinal portion to a locus adjacent the fourth side edge. Theelastic generally extends across the crotch between the second ends ofthe first arcuate portions and the first edge of the garment blanksubassembly. The first and third sections of elastic are typicallystretched when the garment blank subassembly is laid out flat, thesecond section of elastic being relaxed.

In some embodiments, the second section of threads of elastic, which hasbeen described as extending across the crotch, at either or both of the.front and back leg edge portions, is cut or portions of the threads arecut such that the second section, or portions of it, extend from one orboth of the respective first and third sections, generally at thecrotch. In such instance, the length of the second section, in itsessentially relaxed state, may be shorter than the distance separatingthe first and third sections.

Third, the invention comprehends a disposable garment adapted to receivea primary absorbent, the primary absorbent having a liquid permeableinner sheet to be disposed against the user's body, a liquid impermeableouter sheet, and an absorbent member disposed therebetween. Thedisposable garment comprises an outer cover having front and back bodyportions connected by a crotch portion, the crotch portion, when laidout flat, having a length, and at any given point along the length, anda width, the front and back body portions being connected together toform a waist opening and first and second leg openings; and an absorbentcomposite associated with the crotch portion. The outer cover of thegarment comprises a first outer layer. A second inner layer is incontact with the first outer layer. One or more continuous threads ofelastic is disposed between, and secured to, the first and secondlayers. First and third sections of the elastic extend along the firstand second leg openings, thereby to form puckers about the first andsecond leg openings at edges thereof. A second section of the elasticextends across the crotch in an essentially relaxed state, such that thewidth of the crotch portion in the assembly corresponds generally to thewidth of the crotch portion when the crotch portion is laid out flat.

Preferably, the second inner layer has first and second sides, theelastic is disposed on the first side of the second inner layer, and theabsorbent composite is disposed on the thrid side of the second innerlayer.

Also preferably, the first and third sections of the elastic areseparated from the absorbent composite by the second inner layer, withthe second section of elastic being disposed between the first andsecond layers.

In some embodiments, the second layer comprises a body side liner havinga front layer element secured to the front portion of the first layer,and a back layer element secured to the back portion of the first layer,and including an unsecured space between the front layer element and theback layer element, with the second section of elastic disposed in theunsecured space between the front and back portions of the first layer.

Preferably, the elastic defines a first path of traverse across thegarment, and the garment includes at least a second thread of elasticfollowing a second path generally parallel to the first path.

Preferably, the combination of the elastics circumscribe substantialportions of, and potentially encircle the first and second leg openings,at the corresponding edges of the leg openings, thereby providingsubstantially continuous expansible puckering about the leg openings.

Fourth, the invention comprehends apparatus for placing and securing oneor more threads of elastic between first and second layers of acontinuous web in producing a series of garment or other garmentsubassemblies longitudinally along the web, the subassemblies to beseparated from the web. Regarding garments, each garment has a frontportion, a back portion, a crotch portion connecting the front and theback portions, a waist opening and leg openings, the length of a givengarment subassembly, front-to-back, in the continuous web being disposedtransverse to the longitudinal direction of advance of the garmentsubassemblies through the apparatus. Given the foregoing productdescriptions, the apparatus comprises first and second rolls comprisinga nip, for joining elements of the garment subassemblies; first meanssuch as unwind, drive, and guide apparatus, for feeding first and secondwebs comprising corresponding first and second layers of the garmentsubassembly into the nip; an adhesive applicator for placing adhesive onthe second web; a supply of elastic, for example including unwind anddrive apparatus, for supplying one or more threads of elastic for use atthe nip and in contact with the adhesive; a lateral guide, disposed in alateral position with respect to the second web within one inch of thenip and adjacent the second web, for receiving the elastic, for feedingthe elastic to the nip between the first and second webs, and forcontrolling the lateral position of the elastic as the elastic entersthe nip; and a transverse driver for maintaining the lateral guidewithin the one inch of the nip and for driving the lateral guide in atransverse direction across the width of the second web and therebychanging the lateral position of the lateral guide with respect to theweb adjacent the. nip, and thus causing the elastic to follow a path onthe second web corresponding to edges of the leg openings, inregistration with advance of the respective ones of the series ofgarment subassemblies.

Preferably, the lateral guide is disposed within 0.5 inch of the nip,and is positioned to direct the elastic onto the adhesive on the secondweb before the elastic enters the nip.

The apparatus preferably includes a cutter for cutting the leg openings,and thereby creating the edges of the leg openings which correspond inregistration with the lateral positions of the elastic, such that theelastic follows a path on the subassembly parallel to the leg openingsacross the transverse dimension of the garment subassembly to a locus atleast adjacent the crotch.

Fifth, the invention comprehends a method of placing and securing anelastic thread between first and second layers of a continuous web inproducing a series of garment-type assemblies or subassemblies, eachgarment-type assembly or subassembly having at least one opening. Themethod comprises the steps of feeding first and second webs comprisingcorresponding first and second layers of the garment-type assembly intoa nip; applying adhesive on the second web ahead of the nip; supplyingone or more threads of elastic for use at the nip and in contact withthe adhesive; feeding the elastic to a lateral guide, disposed in alateral position with respect to the second web within one inch of thenip and adjacent the second web, and thus receiving the elastic, andfeeding the elastic to the nip between the first and second webs, andcontrolling the lateral position of the elastic as the thread enters thenip; and maintaining the lateral guide within two inch of the nip, anddriving the lateral guide in a transverse direction across the width ofthe second web and thereby changing the lateral position of the lateralguide with respect to the web adjacent the nip, and thus causing theelastic to follow a path corresponding to an edge of the opening, inregistration with advance of the respective ones of the series ofgarment-type assemblies or subassemblies.

The method preferably includes disposing the lateral guide within 0.5inch of the nip, preferably directing the elastic onto the adhesive onthe second web before the elastic enters the nip, and cutting theopening, and thereby creating the edge of the opening which correspondsin registration with the lateral positions of the elastic, such thatonce the opening is cut, the previously-incorporated elastic follows apath generally parallel to the opening across the transverse dimensionof the garment-type assembly or subassembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood and furtheradvantages will become apparent when reference is made to the followingdetailed description of the invention and the drawings, in which:

FIG. 1 is a plan view of a garment subassembly relating to an garment ofthe invention.

FIG. 2 is a plan view of the garment subassembly of FIG. 1, includingthe secondary absorbent in the crotch.

FIG. 3 is a cross section of the garment subassembly taken at 3--3 ofFIG. 2.

FIG. 4 is a cross section of the garment subassembly taken at 4--4 ofFIG. 2.

FIG. 5 is a perspective view of a disposable garment of the invention.

FIGS. 6 and 7 are enlarged cut-away views of a fragment of thesubassembly of FIG. 1, showing detail of the cross-crotch elastics.

FIG. 8 is a side elevation view of an equipment layout for fabricatingand otherwise processing the subassemblies of the invention.

FIGS. 9 and 10 are pictorial views of the nip area of the elevationshown in FIG. 8.

FIG. 11 is a plan view showing the relative transverse positioning ofthe front and back leg elastics along the advancing web while the outercover layer and body side layer are being joined.

FIG. 12 is a plan view as in FIG. 11, showing an alternate pattern forthe elastic threads.

FIG. 13 is a diagram illustrating the elastic guide movement required toattain a given pattern in the final product for various guide to nipdistances.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The following detailed description is made in the context of an articleincluding a disposable garment, and corresponding garment subassemblies,for holding a sanitary pad in place as a primary absorbent during use ofthe garment. It is readily apparent, however, that the garments madeusing the present invention can be employed with other disposablesanitary articles, such as feminine tampons, incontinent garments,diapers, training pants, and the like.

The garment subassembly 10 of FIG. 1 illustrates the preferredembodiment of the two-layer garment subassembly prior to incorporationof the secondary absorbent. The garment subassembly of FIG. 2illustrates the preferred embodiment of the finished garment includingall elements, but before the final steps of assembling the composite toform the garment structure. FIG. 5 shows the finally-assembleddisposable garment structure. Referring to FIGS. 1-3, the garmentsubassembly 10 has an outer cover layer 12 generally defining theoverall length "L1" and width "W1" of the subassembly, and at least onebody side layer(s) 14 secured to the outer cover layer to coveradhesively applied components. The garment subassembly 10 generallyincludes a front body portion 16 terminating at a front waist portion 18as a first edge of the subassembly, a back body portion 20 terminatingat a back waist portion 22 as a second edge of the subassembly, and acrotch portion 24.

Advantageously, the body side layer 14 includes a front layer element 19generally overlying and secured to the outer cover layer 12 on the frontbody portion 16, and a back layer element 21 generally overlying andsecured to the outer cover layer 12 on the back body portion 20. Anunsecured space 23 separates the front layer element 19 from the backlayer element 21.

Referring to FIGS. 2 and 5, for assembling the subassembly of FIG. 2 toform garment 25 as in FIG. 5, a first side edge 26 of front body portion16 is assembled with a first side edge 28 of the back body portion 20 toform a first side seal 30. Similarly, a second side edge 32 of the frontbody portion 16 is assembled with a second side edge 34 of the back bodyportion 20 to form a second side seal 36. The waist portions 18, 22 whenassembled form a waist opening 38 for putting on and taking off thegarment 25. The waist opening 38 is surrounded at least in part by awaist elastic 40. The waist elastic 40 is stretched and attached to thewaist portions 18, 22 in the stretched state. The waist elastic 40 isreleased after attachment to produce waist folds or pleats 42 to allowexpansion of the waist opening 38 so that the garment 25 can fit varioussizes of people. Because users of this invention generally prefer abrief style garment, the front waist portion 18 preferably comes as highas the navel and is level around the wearer's waist. Having the garmentat this height provides a snug fit. Alternative garment styles includebikini (e. g. regular leg cut or french leg cut) and hipster (e.g.regular leg cut or french leg cut).

Referring to FIGS. 1 and 5, the front body portion 16, the back bodyportion 20, and the crotch portion 24, in combination, form left andright leg openings 44 and 46, respectively, which are generally circularor oval in shape in the finally assembled garment 25. The leg openings44 and 46 are formed by cutting away portions of the outer cover layer12, and corresponding portions if any of body side layer 14. Each legopening 44, 46 is surrounded at least in part by a back leg elastic 48,a front leg elastic 50, and a crotch elastic 51 between the back legelastic and the front leg elastic. Each of the respective elastics 48,50, 51 is adjacent the respective one of the edges 52 of thecorresponding leg openings. The front and back leg elastics 48, 50 aresecured between the outer cover layer 12 and the body side layer 14 byadhesive 55. The crotch elastics 51 are secured to outer cover layer 12by adhesive 55. The elastics 48, 50, 51 are in the stretched state whensecured to the outer cover layer 12. Accordingly, when the elastics, theouter cover layer and the body side layer are released after theelastics are secured to the outer cover layer, the elastics produce legfolds or pleats 54 at the edges of the leg openings 44, 46 to allowexpansion of the leg openings 44, 46 to fit various sizes of legs.Between the front body portion and the back body portion in generallythe crotch portion of the garment, an unsecure area is created. Theunsecured area can be substantially unsecured or relatively unsecured incomparison to the attachment of the front and back portions to the firstlayer.

The front body portion 16 may be divided into a front upper portion 56and a front lower portion 58. Similarly, the back body portion 20 may bedivided into a back upper portion 60 and a back lower portion 62. Theupper portions 56 and 60 are preferably designed to include bodyelastics 64 which readily stretch to allow the wearer to put on thegarment 25 and then readily contract to resume the normal release stateof the body elastics. This ensures a close or snug fit to different bodysizes and forms. A number of body elastics 64 are positioned on both thefront and the back portions 56, 60, respectively, at positions betweenthe waist opening 38 and the leg openings 44, 46, so that the garment 25has a good fit, particularly around the body.

The lower body portions 58, 62 generally do not require the spacedelastics as in the upper body portions 56, 60, although the elastics maybe used.

The width of the crotch portion 24 between the left and right crotchelastics 51 should be wide enough to accommodate laying the primaryabsorbent 66 between the edges 52 without having the primary absorbent66 obstruct the crotch elastics 51. This allows the crotch elastics 51to contract and draw up the sides of the crotch about the primaryabsorbent, to thus accommodate the thickness of the primary absorbent66, and to give surface area within the crotch portion 24 of thegarment, adjacent edges 52, to contain leakage from the primaryabsorbent 66.

The width of the crotch portion 24 between the elastics 51 should not beso wide as to seem bulky or uncomfortable. A suitable width is at leastabout 2.75 inches (70 mm) between the crotch elastics. Width of crotchportion 24 is advantageous from about 3 inches (76 mm) to about 3.5inches (89 mm). Preferably, the width is about 3 inches (76 mm).

Preferably, the crotch elastics 51 are from about 0.375 inch (10 mm) toabout 0.625 inch (16 mm) wide. More preferably, the width is about 0.5inch (13 mm). Preferably, ruffle material on the edge of the legopenings 44, 46 outside the leg elastics 48, 50 and crotch elastics 51is less than about 0.25 (6 mm). More preferably, the ruffle material isless than about 0.125 inch (3 mm). It is most desirable to eliminate anyruffle material from the edges of the leg openings 44, 46, asillustrated in FIG. 5.

The overall width of the crotch portion 24 includes the width betweenthe left and right crotch elastics 51, the width of the crotch elastics,and any ruffle material outside the crotch elastics to the edges 52 ofthe leg openings. Preferably, the overall width of the crotch portion 24should be at least about 4 inches (102 mm).

FIG. 2 shows the garment subassembly 10 of FIG. 1 with a secondaryabsorbent 68 secured in the crotch portion 24, over the outer coverlayer 12 and parts of the front and back layer elements 19, 21 of thebody side layer 14. The width of the secondary absorbent 68 is sized inrelation to the width of the crotch portion 24. Preferably, the width ofthe secondary absorbent 68 is at least the width of the crotch portion24 between the crotch elastics 51. More preferably, the width of thesecondary absorbent is equivalent to the overall width of the crotchportion 24.

The secondary absorbent 68 should have sufficient capacity to absorb anyflow or seepage of body fluid around or through the primary absorbent66. The secondary absorbent 68 should preferably have a capacity andthickness substantially less than that of the primary absorbent 66, thusproviding a nonbulky and flexible fit. The secondary absorbent 68 shouldhave a total capacity of about one-half the capacity of the primaryabsorbent 66. Preferably, the secondary absorbent 68 should have a totalcapacity of at least about 3 grams and not more than 6 grams. Morepreferably, the total capacity of the secondary absorbent 68 should befrom about 4 grams to about 6 grams. However, the basis weight of, orthe type of, the secondary absorbent 68 should be selected to provideresistance to flexibility of less than around 400 grams, as measured byINDA Standard Test method IST 90.3-92 Standard Test Method forHandle-O-Meter Stiffness of Nonwoven Fabrics.

The secondary absorbent has a low stiffness. The low stiffness allowsthe absorbent and its barrier to remain attached to the conformableouter cover layer 12 and the body side layer 14 which conform to a widerange of body sizes and shapes. Preferably, the secondary absorbent hasa stiffness of less than 400 grams along any axis tested, morepreferably less than 300 grams along any axis and less than 100 gramsalong the axis parallel to the waist opening. The secondary absorbentalone will have a stiffness of less than 250 grams and preferably lessthan 100 grams along any axis and more preferably less than 75 gramsalong the axis parallel to the waist opening.

The overall length of the secondary absorbent 68 should be adequate toextend beyond the ends of the primary absorbent 66, in order to beproperly positioned to receive liquid which flows or seeps around theedges of the primary absorbent 66. This overall length is typically atleast about 15 inches (382 mm) thus extending beyond the crotch portion24 along the longitudinal centerline A--A of the subassembly 10. Thelength should be in the range of about 15 inches (382 mm) to about 19inches (484 mm). Preferably, the length of the secondary absorbent 68 isabout 17 inches (433 mm).

The width of the secondary absorbent 68 beyond the crotch portion 24should be at least as wide as the width of the crotch portion 24. Thewidth of the secondary absorbent 68 may be narrowed beyond the crotchportion 24 but may thus compromise the containment of liquid flowing orseeping from the primary absorbent. More preferably, the width outsidethe crotch portion is wider than in the crotch portion, and is fromabout 5 inches (127 mm) to about 12 inches (306 mm), alternatively fromabout 5.5 inches (140 mm) to about 7.5 inches (191 mm). Preferably, thewidth is about 6.5 inches (165 mm).

Referring to FIGS. 2, 3, and 4, the waist elastics 40, the body elastics64, and the leg elastics 48, 50, are generally covered by the front andback layer elements 19, 21 of the body side layer 14.

Both outer cover layer 12 and body side layer 14 are compliant and softfeeling to the wearer. The following description of materials from whichthe outer cover layer 12 can be made applies equally to the material ofthe body side layer 14.

The outer cover layer 12 may be liquid pervious, permitting liquids toreadily penetrate into its thickness, or impervious, resistant to thepenetration of liquids into its thickness. Outer cover layer 12 may bemade from a wide range of materials, such as natural fibers (e.g. woodor cotton fibers), synthetic fibers (e.g. polyester or polypropylenefibers) or from a combination of natural and synthetic fibers orreticulated foams and apertured plastic films. The outer cover layer 12may be woven, nonwoven or film such as spunbonded, carded, or the like.A suitable outer cover layer 12 is carded, and thermally bonded by meanswell known to those skilled in the fabric art. Alternatively, the outercover layer 12 is derived from a spunbonded web. In preferredembodiments, the outer cover layer is spunbonded polypropylene nonwovenwith a wireweave bond pattern having a grab tensile of 19 pounds asmeasured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 gramsand CD value of 4.4 grams using TAPPI method T402. Such spunbondedmaterial is available from Kimberly-Clark Corporation, Roswell, Ga. Theouter cover layer 12 has a weight of from about 0.3 oz. per square yard(osy) to about 2.0 osy, preferably about 0.7 osy.

The position and shape of the leg openings 44, 46 are important to avoidtightness in the crotch and groin area of the wearer, to obtain adequatebuttocks coverage, and to prevent the garment 25 from tilting forward,e.g. tilting such that the front waist edge dips lower in relationshipto the back waist edge. FIGS. 1 and 2 illustrate the most preferreddesign for leg fit and buttocks coverage. The shape of the curve acrossthe top of the leg is important. If the curve is too deep, the garment25 will shift downward and backward resulting in a short front waist,increased back length and bagginess in the seat of the garment. Thiswould cause the garment 25 to appear tilted when worn as evidenced by anunevenness around the waist of the wearer.

Thus the majority of the edge 70 of the front portion of each legopening 44, 46 is defined by a straight section 72 having a length "L2"at least about 70% of the length "L3" of the entire edge 70. Thestraight section 72 should form an angle with the centerline A--A ofbetween about 75° and about 100°, and most preferably about 90°. Theessentially perpendicular angle formed between the centerline A--A andthe front leg opening is measured using a line extending through the endpoints of the elastic sections.

With the garment subassembly 10 laid out flat as in FIG. 2, the majorityof the edge 74 of the back portion of each leg opening is defined by astraight section 76 having a length "L4" at least about 70% of thelength "L5" of the entire edge 74. The straight section 76 forms anacute angle with the longitudinal centerline A--A of the subassembly 10.More preferably, the straight section 76A of the edge 74 forms an acuteangle α with the centerline A--A of the garment 25 of between about 50°and 65° and most preferably about 60°. The acute angle is measured usinga line extending through the end points of the elastic sections.

The majority of the edge 78 of the crotch portion of each leg opening44, 46 is defined by a straight section 80 having a length "L6."Preferably, the straight sections 80 are straight for at least about 70%of the entire lengths "L7" of the respective edges 78.

Referring to FIG. 1, each back leg edge portion 74 includes an arcuatesection "A1" extending from one end 81 of the respective straightsection 76 to a second end 82, thus connecting the respective back legedge portion to the back end of edge 78 of the respective crotchportion.

Each front leg edge portion 70 includes an arcuate section "A2"extending from one end 84 of the respective straight section 72 to asecond end 86 connecting the respective front leg edge portion 70 to thefront end of edge 78 of the respective crotch portion.

The shape of the arcuate section "A2" at the inner groin area isimportant. If the arc is too shallow, tightness may be experienced atthe inner groin area.

The preferred narrow crotch width reduces coverage of the buttocks. Tocompensate for such reduction, the arcuate section "A1" is preferablyadjusted toward back waist portion 22, such that the end 82 of thearcuate section "A1" should be positioned slightly forward of centerlineB--B as shown in FIGS. 1 and 2.

The waist, back leg, front leg and body elastics 40, 48, 50, 64respectively are attached to the garment subassembly 10, generallybetween the outer cover layer 12 and the body side layer 14, usingapparatus and processes described hereinafter.

Materials suitable for use as the elastics include a wide variety, butnot limited to, of elastic threads, yarn rubber, flat rubber (e.g. asbands), elastic tape, film-type rubber, polyurethane, and, tape-likeelastomer, or foam polyurethane or formed elastic scrim. Each elasticmay be unitary, multipart, or composite in construction. Threads orribbons, where used, may be multiple and may be applied as a composite.The elastomerics used in the elastics may be latent and nonlatent.

Waist elastic 40 is typically about 0.5 inch (13 mm) wide. The elasticmay comprise threads, ribbons, a film, or composite. The threads orribbons may be multiple and may be applied as a composite. Preferably,the waist elastic is threads, more preferably four threads are used asthe elastic and the threads are spaced about 0.17 inch (4.3 mm) apart.The threads may be made of any suitable elastomeric material. Onesuitable material is spandex such as Lycra® threads available fromDupont located in Wilmington, Del. Preferably, suitable waist elasticsinclude threads having a total decitex (g/1000 m) of about 3760 for 0.5inch (13 mm) wide elastic. The decitex may vary for each element ofelastics. Adhesive 55 is used to bond the elastic between the outercover layer 12 and the body side layer 14. A suitable adhesive includes,for example Findley H2096 hot melt adhesive, available from FindleyAdhesives, Milwaukee, Wis.

The leg elastics 48, 50, and crotch elastic 51, including multiplethreads in each, are typically about 0.5 inch (13 mm) wide. The elasticmay comprise threads, ribbons, a film or composite. The threads,ribbons, etc., may be multiple and may be applied as a composite. Thefront leg elastics and the crotch elastics may be threads, preferablynumbering three threads which are spaced about 0.05 to about 0.50 inch,preferably about 0.10 to about 0.20, more preferably about 0.17 inch(4.3 mm) apart. Back leg elastics numbering up to six threads may have awidth of about 0.75 inch (19 mm) and a thread spacing of about 0.05 toabout 0.75 inch, preferably about 0.10 to about 0.20, more preferably ofabout 0.15 inch (3.8 mm) apart. The threads may be made of any suitableelastomeric material. One suitable material is spandex such as Lycra®threads available from Dupont, Wilmington, Del. Preferably, suitable legelastics include threads having a total decitex (g/1000 m) of about 3760for a 0.5 inch (13 mm) wide elastic. The decitex may vary for eachelement of elastics. Adhesive 55 is used to bond the several elastics48, 50 to the outer cover layer 12, the body side layer 14, and thesupport sheet 53.

To provide a snug leg fit and to draw up the sides of the crotch portion24 to a cradle to receive the primary absorbent, the leg elastics 48,50, and the crotch elastics 51, are elongated when applied to the layers12 and 14 respectively. Preferably, the leg elastics 48, 50 are appliedin multiple segments, with the amount of elongation of each segmentwhile being incorporated into the subassembly 10 being determinedaccording to the position to be occupied by the respective segment. Inthe case of only front and back leg elastics, the front leg elastics areadvantageously elongated less than the back elastics. In the case offront elastics, back elastics, and crotch elastics, the front and crotchelastics are preferably elongated less than the back elastics.Preferably, the elongation of front and crotch elastics are minimal upto between about 100% to about 300%, preferably depending on the decitexof the elastic threads used to about 150% and the elongation of backelastics along the leg openings are minimal to between about 100% toabout 300% and preferably depending on the decitex of the elasticthreads used to about 250%. The elongations may vary for separateelements and still be within the overall elongation for the composite ofelastic elements. The differing tensions allow easier attachment of theprimary absorbent pad 66, less tightness in the groin area, and lessbunching of the crotch portion 24 caused by high leg elastic retraction.The back leg elastic is under higher elongation to help keep the seat ofthe garment from creeping up with movement during use. In certain cases,the elongation of the front and back elastics may be minimal when theouter layer is elastic and the front and back elastics are dimensionedto be that of the minimum size of the wearer.

Referring now to FIGS. 1, 6, and 7, the suggested six (back) and three(front) threads of elastic on the respective back and front leg elastics48 and 50 are each represented as single element of elastic. Thefollowing description of the characteristics and use of the singlethreads applies to the usual multiple threads suggested above.

The composite of the elastics extending about each of the leg openings44 and 46 comprises a portion of the back leg elastics 48, a portion ofthe front leg elastics 50, and one of the left and right crotch elastics51. Referring specifically to FIGS. 1, 6, and 7, the back leg elastic 48extends, as a first section 48A, from a first locus 92 at or adjacentthe edge 28 of the subassembly, width-wise across the subassembly at asubstantially consistent acute angle α with the centerline A--A thattakes it toward a first edge of the subassembly at front waist portion18, and generally following the back edge 74 of the leg opening 46 alongthe straight section 76A and onto the first arcuate section "A1" towardthe crotch portion 24, generally terminating in the first arcuatesection "A1," at or near the crotch portion 24. Back leg elastic 48extends, as a second section 48B, from the first arcuate section "A1"across the crotch portion to the second arcuate section "A1." From thesecond arcuate section "A1," the back leg elastic 48 extends, as a thirdsection 48C, at an acute angle α with the centerline A--A away from thefront waist portion 18, and generally following the back edge 74 of theleg opening 44 along the straight section 76B to a second locus 94 at oradjacent edge 34.

In the flat configuration shown for the subassembly in FIGS. 1, 6, and7, sections 48A and 48C are elongated to between about 100% to about300%, preferably depending on the decitex of the elastic threads usedabout 250%, while section 48B is substantially relaxed, and under nosubstantial elongation. Preferably, section 488 includes a modest amountof slack in the elastic.

The front leg elastic 50 extends, as a first section 50A, from a thirdlocus 96 at or adjacent the side edge 26 of the subassembly width-wiseacross the subassembly and generally following the front leg edgeportion 70 along its longitudinal straight section 72A, and onto thefirst arcuate section "A2" toward the crotch portion 24, generallyterminating in the first arcuate section "A2," at or near the crotchportion 24. Front leg elastic 50 extends, as a second section 50B, fromthe first arcuate section "A2" across the crotch portion to the secondarcuate section "A2." From the second arcuate section "A2," the frontleg elastic 50 extends, as a third section 50C, width-wise across thesubassembly and generally following the front leg edge portion 70 alongits longitudinal straight section 72B to a fourth locus 98 at oradjacent side edge 32. In the flat configuration shown for thesubassembly in FIGS. 1, 6, and 7, sections 50A and 50C are elongated tobetween about 100% to about 300%, preferably depending on the decitex ofthe elastic threads used about 150%, while section 50B is substantiallyrelaxed, and under no substantial elongation. Preferably, section 50Bincludes a modest amount of slack in the elastic.

Thus, in the embodiment seen in FIG. 1, the front and rear leg elasticsextend across the width W1 of the subassembly 10 as one or morecontinuous threads.

The crotch elastics 51 extend generally between the back and front legelastics 48 and 50, with respective ends of the crotch elasticsgenerally being disposed at or near the arcuate sections "A1" and "A2."Accordingly, the properties of the elastics about each leg openingresult from the combined contributions of the respective back legsection (e.g. 48A), the respective front leg section (e.g. 50A), and therespective crotch elastic 51.

The reason for providing leg elastics in multiple sections is at leasttwo-fold. First, using multiple sections of elastics facilitates placingof the elastics on the outer cover layer 12 while maintainingadvantageous production speeds. As suggested in FIGS. 1, 8, and 9, thesubassembly of e.g. FIG. 1 is made as a sequence of such subassembliesin a continuous web 100, with the width "W1" of the subassembly disposedin the "with machine" direction of the processing apparatus. In sucharrangement, the front and back waist elastics 40, the front and backbody elastics 64, and the front and back leg elastics 48, 50 can all beassembled into the subassembly by appropriate continuous feeding ofrespective continuous threads of elastics into the processing apparatusin the "with machine" direction while the web 100 continuously advancesin the "with machine" direction at a constant speed.

Given the orientation of the crotch elastics at essentially 90° to thedirection of advance of the web 100, placing the crotch elastics as aportion of a continuous element of either the front or back leg elasticswould suggest either (1) momentarily and regularly stopping the advanceof the web 100 while the crotch elastic is fed into place, or (2)severely slowing the web 100 and severely driving an elastics guide, ina direction transverse to the web in order to apply the crotch elasticwhile the web was thus slowed. In either scenario, severe stresses wouldbe placed on the respective drive apparatus, as well as on the web. Theinvention contemplates, rather, that the crotch elastics are optionallyplaced in the subassembly 10 as a separate operation placing separateelastics segments, where the crotch elastics segments are firstelongated and oriented transverse to the web 100, and are then placed onthe web as the web passes the appropriate operating station (not shown)subsequent to placing the leg, body and waist elastics in thesubassembly, though the sequence of placing the elastics is notcritical.

Referring now to FIGS. 8-11, a first continuous web, which ultimatelybecomes cover layer 12, is presented against the assembly roll 102 byturning roll 104. A second continuous web, which ultimately becomes bodyside layer 14, passes under adhesive applicator 106 and over turningrolls 108 and 110, and is pressed against the assembly roll 102 byturning roll 110. Elastic threads 112 are fed from a continuous supply114 of elastic thread, through feed nip 116, through thread guides 118and sets of guide fingers 120A and 120B, and between cover layer 12 andbody side layer 14 at the nip formed by assembly roll 102 and turningroll 110.

Referring especially to FIGS. 9 and 10, thread guides 118 andcorresponding sets of guide fingers 120A and 120B are elements oflateral guides 122A and 122B respectively. Each of the lateral guides122A and 122B is mounted on a transverse slide bar 124 for slidingtransverse to the with machine direction of travel of the webs. Eachlateral guide 122 is connected to a transverse drive mechanism 136including linkage arms 128 and 130, vertical drive shaft 132, and a camfollower (not shown). The cam followers follow the corresponding camsinside the respective cam housings. The cams are linked to the machinedrive shaft 140 by drive belt 142. Thus, the cams, and correspondinglythe thread guides and the sets of guide fingers, move transversely withrespect to the with machine direction of the webs as the drive shaftturns. The end result is that rotation of the processing line driveshaft 140 effects transverse motion of the thread guides and the sets ofguide fingers, as indicated by the arrows 117 in FIG. 10, in cooperationwith the design of the cams and cam followers.

Referring to FIG. 8, the guide fingers 120 are positioned close to thenip 144 so that they closely control the transverse positions of theelastics with respect to the webs 12 and 14 as the webs 12 and 14 enterthe nip 144 and correspondingly trap the elastics between them, fixingthe position of the elastics between them by means of adhesive 55 asshown in FIG. 3. Accordingly, the guide fingers 120 are preferablyphysically positioned, and provide guidance to the threads of elastic,within two inch of the nip 144. To the extent the fingers can be placedcloser to the nip 144, they provide more positive guidance to theelastic. By careful design of the guide fingers 120, and by carefulcontrol of the positioning of the guide fingers 120 with respect to nip144, the guide fingers 120 can be advantageously positioned within twoinches, advantageously within 0.75 inch of the line of contact definedat the nip between roll 102 and 110. Additionally, body elastics 64 andwaist elastics 40 can be incorporated at nip 144 in the conventionalmanner of providing stationary feeds and guides at the nip.

The limitation on how close the guide fingers 120 can be placed to thenip is controlled by the ability to design fingers which canaffirmatively guide the threads of elastic while avoiding having thefingers themselves drawn into the nip. The criticality of urging thefingers as ultimately close as possible to the nip can be attenuated bydirecting the threads 112 onto the adhesive-coated layer 14 ahead of nip144, preferably instantaneously ahead of the nip 144, as suggested bythe depiction in FIG. 8. By directing the threads of elastic onto layer14 ahead of the nip, the open distance spanned by the threads betweenthe fingers 120 and the adhesive-coated layer 14 is minimized, beingheld to less than 0.5 inch, for example 0.25-0.375 inch (6 mm to 10 mm).

The transverse movement of the lateral guides 122, and thus fingers 120,as the webs advance along the processing line, creates transversepositioning of the elastics threads 112 with respect to the with machinedirection of the advancing webs 12 and 14. FIG. 11 shows the pattern oftransverse movement of the sets of guide fingers 120A and 120B relativeto the movement of the web in the with machine direction, along theprocessing line. In FIG. 11, the sets of fingers 120A and 120B aredepicted at several locations along the front and back edges of the legopenings 44, 46, to indicate that it is the positioning of the sets offingers 120A and 120B, and the dynamic changing of that positioning bythe drive mechanism 126, that determines the instantaneous transverselocation of the elastics in the web at any point and time while theelastics are being placed in the web at nip 144 as shown in FIGS. 8-11.Comparing FIGS. 1, 10, and 11, it is seen that the set of fingers 120Agenerally places the threads of the back leg elastics generally parallelto each other in the web, while the set of fingers 120B generally placesthe threads of the front leg elastics generally parallel to each otherin the web, both along their respective portions of the designed pathsdefining the front 70 and back 74 edges of. the leg openings 44 and 46.

FIG. 13 is a diagram of the transverse movement required of guide 122,in order to produce a given elastic thread pattern, given threedifferent guide to nip distances. FIG. 13 illustrates that because ofthe gap between the elastic guide and the nip, the elastic guidemovement never matches the required elastic pattern. The curves B, C,and D show that for a given elastic pattern, the guide movementamplitude and rates of change increase and become progressively moretortuous as the distance from the guide to the nip increases. Large,abrupt changes in guide movement cause shock and vibration and thus aredeleterious to machinery. Therefore, it is advantageous to keep theguide as close to the nip as possible.

The threads of elastic deviate slightly from their parallelrelationships with each other as the elastic threads traverse paths thatdeviate from the with machine direction, the distance between thethreads 90 being generally constant as they emerge from the fingers 120.Such deviations from the parallel, resulting from the cross machinetraverse of the elastics, are included herein within the phrase"generally parallel" as respects the relationships of the threads ofelastic to each other.

It will be understood that FIG. 11 represents only one garment in thecontinuous sequence of garment subassemblies 10 contained in the web 100passing through nip 144. It will also be understood that the web passingthrough the nip 144 is further acted upon at cutter 146 as shown in FIG.8 to cut away material from the web 100 in creating the leg openings 44and 46.

In general, then, webs 12 and 14 are provided as substantially endlessrolls from unwind stands (not shown). Web 14 is typically provided asfront and back layer elements 19 and 21. Space 23 separates the elements19 and 21, and generally corresponds with the central area of the crotchportion and the portion of the web 12 which is cut out to form legopenings 44 and 46. Adhesive 55 is applied to the front and backelements 19 and 21 of web 14 by adhesive applicator 106. Webs 12 and 14are joined adhesively, with elastic threads being interposed betweenwebs 12 and 14 at nip 144, and with space 23 interposed between thefront and back elements 19, 21 of the body side layer 14. The transversepositions of the elastics change according to a pre-set path oftransverse movements, driven by the drive shaft 140 which drives andtimes the several operations along the processing line. The threads ofelastic 112, as placed by the guide fingers 120, traverse respectivepaths that ultimately follow the front and back edges of the legopenings 44 and 46, as defined at cutter 146, in registration with theadvance of the web, and accordingly, with the advance of the series ofgarment subassemblies 10 being defined in the web at nip 144 and cutter146. The portions of the threads of elastic located along the front andback edges of the leg openings are stretched. The portions traversingthe crotch portion are substantially relaxed. The crotch portions of theelastic are separately placed in the subassembly 10 at a laterprocessing station, preferably downstream from the cutter 146.

A second embodiment of the subassembly is illustrated in FIG. 12. In thesecond embodiment, the front edge 148 of back layer element 21 isdisposed rearwardly of that same edge 148 as depicted in the embodimentof FIG. 11, while the guide fingers 120A traverse the same path as inFIG. 11. Accordingly, as the threads of elastic 112 extend across thecrotch portion 24, the threads 112 are guided forwardly of edge 148,into unsecured space 23, and are thus not held between the layers 12 and14, and are not controlled by the adhesive on layer 14. Rather, thetension is maintained on the threads of elastic 112 across the crotchportion 24, such that the threads retract along the edge 148 of thelayer element 21 in a configuration that loosely resembles a rope undertension. The rope or the at least one elastic strand of the rope issubsequently cut such that the cut portions of the threads retract topositions generally defined by the intersection of the edge 148 of theback layer element and the path of the threads adhesively held betweenlayer and the back layer element. Thus, the at least one cut threads 112generally include loose intermediate ends 150 after being cut, as shownin FIG. 7.

The front layer element 19 is applied along the back edge 178 of the legopening in a manner similar to the application of the back layer element21.

Having thus described the invention in full detail, it will be readilyapparent that various changes and modifications may be made withoutdeparting from the spirit of the invention. All such changes andmodifications are contemplated as being within the scope of the presentinvention, as defined by the following claims.

What is claimed is:
 1. A disposable garment adapted to receive a primaryabsorbent, the disposable garment comprising:(a) an outer cover havingfront and back body portions connected by a crotch portion, the crotchportion, when laid out flat, having a length and a width, the front andback body portions being connected together to form a waist opening andfirst and second leg openings, the outer cover comprising a first layer,and a first elastic attached to the first layer, first andthird-sections of the elastic extending along the first and second legopenings, to form puckers about the first and second leg openings atedges thereof, a second section of the elastic extending across thecrotch portion in a substantially relaxed state, such that the width ofthe crotch portion in the disposable garment corresponds generally tothe width of the crotch portion when the crotch portion is laid outflat; (b) an absorbent composite associated with the crotch portion and(c) a second layer, the second layer having first and second surfaces,the elastic being disposed on the first surface of the second layer andthe absorbent composite being disposed on the second surface of thesecond layer.
 2. a disposable garment as in claim 1, the first and thirdsections of the first elastic being separated from the absorbentcomposite by the second layer.
 3. A disposable garment as in claim 1,the second section of the first elastic being disposed between the firstand second layers.
 4. A disposable garment as in claim 1, the secondlayer comprising a body side liner having a front layer element attachedto the front portion of the first layer, and a back layer elementattached to the back portion of the first layer, and including anunsecured space between the front layer element and the back layerelement.
 5. A disposable garment as in claim 4, the second section ofthe elastic being disposed in the unsecured space between the front andback portions of the first layer.
 6. A disposable garment adapted toreceive a primary absorbent, the disposable garment comprising:(a) anouter cover having front and back body portions connected by a crotchportion, the crotch portion, when laid out flat, having a length and awidth, the front and back body portions being connected together to forma waist opening and first and second leg openings, the first and secondleg openings having respective front and back leg edge portions andcorresponding front and back sides, the outer cover comprising a firstlayer; (b) an absorbent composite associated with the crotch portion;(c) a first elastic attached to the first layer, and extending from afirst locus adjacent the first back side of the first leg opening, as afirst section of the first elastic, along the width of the disposablegarment, and generally following the first back leg edge portion of thefirst leg opening toward the crotch, as a second section of the firstelastic across the crotch, and as a third section of the first elasticaway from the first section and generally following the second back legedge portion, to a second locus adjacent the second back side of thesecond leg opening; and (d) a second layer, the second layer havingfirst and second surfaces, the elastic being disposed on the firstsurface of the second layer and the absorbent composite being disposedon the second surface of the second layer, the first and third sectionsof the first elastic being separated from the absorbent composite by thesecond layer.
 7. The disposable garment of claim 6, the second sectionof the elastic extending across the crotch portion in a substantiallyrelaxed state, such that the width of the crotch portion in thedisposable garment corresponds generally to the width of the crotchportion when the crotch portion is laid out flat.
 8. The disposablegarment of claim 6, the absorbent composite having a capacity of fromabout 3 grams to about 6 grams.
 9. The disposable garment of claim 6,the first and third sections of the first elastic being stretched andthe second section of the first elastic being substantially relaxed whenthe disposable garment is laid out flat.
 10. The disposable garment ofclaim 6, including a second elastic extending from a second locusadjacent the first front side as a first section of the second elastic,along the width of the disposable garment and generally following thefirst front leg edge portion toward the crotch, as a second section ofthe second elastic across the crotch, and as a third section of thesecond elastic away from the first section and generally following thesecond front leg edge portion, to a fourth locus adjacent the secondfront side.
 11. The disposable garment of claim 10, including a thirdelastic having a length, a first end of the third elastic adjacent saidfirst elastic near the first leg opening and a second end of the thirdelastic adjacent said second elastic near the first leg opening.
 12. Thedisposable garment of claim 11, including a fourth elastic having alength, a first end of the fourth elastic adjacent said first elasticnear the second leg opening and a second end of the fourth elasticadjacent said second elastic near the second leg opening.
 13. Adisposable garment comprising:(a) an outer cover having front and backbody portions connected by a crotch portion, the crotch portion, whenlaid out flat, having a length, a width and along the width opposingcrotch edge portions, the front and back body portions being connectedtogether to form a waist opening and first and second leg openings; (b)a secondary absorbent associated with the crotch portion, and adapted toreceive a primary absorbent, having capacity and thickness substantiallyless than that of the primary absorbent and sufficient capacity toabsorb any flow or seepage of body fluid not absorbed by the primaryabsorbent; and (c) a primary absorbent associated with secondaryabsorbent,the outer cover comprising a first layer, and a first elasticattached to the first layer, first and third-sections of the elasticextending along the first and second leg openings, to form puckers aboutthe first and second leg openings at edges thereof, a second section ofthe elastic extending across the crotch portion in a substantiallyrelaxed state, such that the width of the crotch portion in thedisposable garment corresponds generally to the width of the crotchportion when the crotch portion is laid out flat.
 14. A disposablegarment as in claim 13, the secondary absorbent having a stiffness ofless than 400 grams along any axis tested and less than 100 grams alongan axis parallel to the waist opening.
 15. A disposable garment as inclaim 13, the secondary absorbent having a capacity of from about 3grams to about 6 grams.
 16. A disposable garment as in claim 13, thecrotch edge portions having a straight section for a majority of thecrotch edge portions.
 17. A disposable garment as in claim 13, theprimary absorbent having a liquid permeable inner sheet to be disposedagainst a user's body, a liquid impermeable outer sheet and anattachment means for attaching the primary absorbent to the secondaryabsorbent.
 18. A disposable garment as in claim 13, comprisingadditionally a second layer, the second layer having first and secondsurfaces, the elastic being disposed on the first surface of the secondlayer and the secondary absorbent being disposed on the second surfaceof the second layer.
 19. A disposable garment as in claim 18, the firstand second sections of the first elastic being separated from thesecondary absorbent by the second layer.
 20. A disposable garment as inclaim 18, the second section of the first elastic being disposed betweenthe first and second layers.
 21. A disposable garment as in claim 18,the second layer comprising a body side liner having a front layerelement attached to the front portion of the first layer, and a backlayer element attached to the back portion of the first layer, andincluding an unsecured space between the front layer element and theback layer element.
 22. A disposable garment as in claim 21, the secondsection of the elastic being disposed in the unsecured space between thefront and back portions of the first layer.